DUT-E, SK DUT-E operation manual
FUEL LEVEL SENSORS
DUT-E AF
DUT-E 232
DUT-E 485
DUT-E CAN DUT-E A5
DUT-E A10
DUT-E I
SK DUT-E
OPERATION MANUAL
(includes Service DUT-E utility user manual
)
Version 6.0
Contents
Contents
1.4.4 Specifications of DUT-E 232 and DUT-E 485 output signal .................................. 19
DUT-E fuel level sensors
Operation manual. Version 6.0 2
Contents
DUT-E fuel level sensors
Operation manual. Version 6.0 3
Contents
DUT-E fuel level sensors
Operation manual. Version 6.0 4
Terms and Definitions
GPS is a US-made satellite geographical positioning system. Signals from GPS satellites enable the Customer’s GPS receiver to calculate its current geographical coordinates, speed and its travel direction.
GLONASS is a Russian-made navigation system. Its basic difference from the GPS system is that the orbital rotation of GLONASS satellites is not synchronous with the rotation of the Earth and this provides for their greater stability.
CAN (Controller Area Network) is a digital bus-type interface that complies with ISO 11898-
1:2003 International Standard.
Various high-level protocols such as J1939, CANopen, DeviceNet, CAN Kingdom etc. may be used to transmit data. CAN bus is designed to integrate various electronic control units and sensors into a single network both in industrial automation systems and in the automobile industry.
Vehicle CAN bus is widely used to obtain vehicle operation data in GPS/GLONASS vehicle tracking systems.
K-Line is a diagnostic interface for data exchange between electronic control units (ECU) and diagnostic port of the vehicle. Is used in ISO 9141 and ISO 14230 protocols which are the part of OBD-II standard.
According to ISO 9141 protocol L-Line is used to send requests to ECU and K-Line is used to receive diagnostic data from ECU. According to
ISO 14230 protocol L-Line is not used while K-Line works for both directions (sending requests and receiving data from ECU).
K-Line is as well used for configuration of DUT-E AF and DUT-E CAN fuel level sensors, DFM fuel flow meters and other telematics hardware.
PGN (Parameter Group Number) parameter group number that determines the contents of particular CAN bus message according to SAE J1939. PGN acronym is used for identification of
CAN bus messages.
S6 is the vehicle onboard data bus developed by TECHNOTON to enable integrating the GPS/GLONASS-based vehicle monitoring system into the vehicle electrical equipment. It comprises a set of cables, interfaces and protocols. Physically, it is implemented on the basis of CAN 2.0B (ISO 11898-
1:2003) and K-Line (ISO 9141). S6 bus data exchange protocol complies with SAE J1939
International Standard.
To get more details on S6 telematics bus visit http://s6.jv-technoton.com/en/
DUT-E fuel level sensors
Operation manual. Version 6.0 5
SPN (Suspect Parameter Number) is the number of particular parameter of CAN bus message according to SAE J1939. Each SPN has its determined name, number of data bytes, type of data, numerical value. SPN acronym is used for identification of parameters of CAN bus messages.
Protocol is a set of logic-level conventions that enables to establish a connection and carry out data exchange between two or more devices connected to this network. These conventions establish a uniform method of data transmission and elimination of errors.
Tracking device is an element of the vehicle tracking system performing the functions of reading data from standard and additional sensors mounted on the vehicle by the manufacturer, reception of signals of coordinates from navigation satellites and transmission of data to the Service Server.
Transport telematics (Vehicle telematics) is a satellite vehicle monitoring based on
GPS/GLONASS navigation systems and technologies and hardware of cellular and/or radio communication and digital maps. Is used for optimization of logistics and in automated fleet operation systems.
Vehicle is an object controlled by the Vehicle Tracking System. This is generally a truck, a bus or a tractor, sometimes a locomotive, a ship, a utility vehicle. From the point of view of Vehicle
Tracking System, static equipment such as diesel generators, heating boilers, burners, and so on are considered vehicles.
S6 Unit is an element of vehicle on-board equipment compatible with S6 bus.
DUT-E fuel level sensors
Operation manual. Version 6.0 6
Introduction
The Operation Manual contains guidelines and rules which refer to DUT-E fuel level sensors
(hereinafter DUT-E) and SK DUT-E service kit (hereinafter SK DUT-E) developed by
JV Technoton , Minsk, Belarus.
The manual contains information on design, operation principle, specifications and instructions on installation, use and maintenance of DUT-E. The manual defines SK DUT-E connection and usage guidelines as well as Service DUT-E utility (version 3.25 and higher) installation and use.
smart sensors for fuel telematics. DUT-E sensors are used for accurate level measurement in fuel tanks of vehicles and stationary tanks.
SK DUT-E used for communication of sensor and PC for setting and configuration.
DUT-E key features:
• conformity with European and national automotive standards and directives;
• measuring probe length reduction without min/max recalibration *;
• measuring probe length extension up to 6 m with additional sections;
• ergonomic bayonet mount allows to save installation time;
• unique bottom spring for better mounting rigidity;
• filter for secure protection from mud;
• full set of mounting accessories and connection cable included;
• adjustable temperature correction for automatic measurement correction based on ambient temperature **;
• self-diagnostics feature to monitor data validity **;
• possibility of integration into telematics bus (SAE J1939 protocol) ***;
• built-in voltage stabilizer – output signal does not depend on vehicle power supply voltage;
• reverse polarity and short circuit protection of any output to vehicle electrical system and chassis;
• sealing possibility to avoid unauthorized intrusion and tampering;
• durability and reliability confirmed by financial guarantee.
* DUT-E A5/A10/I.
** DUT-E AF/232/485/CAN.
*** DUT-E CAN.
DUT-E fuel level sensors
Operation manual. Version 6.0 7
See Figure 1 for identification codes for DUT-E ordering.
Figure 1 —DUT-E order identification codes
Examples of DUT-E ordering identification codes:
Fuel level sensor DUT-E A10 L=700 mm,
(output voltage from 1.5 to 9.0 V, measuring probe length 700 mm).
Fuel level sensor measuring head DUT-E 232 Base,
(RS-232 serial interface, without standard measuring probe).
* Corresponds to the external height of most common tanks.
Upon Customer request DUT-E sensors can be produced with any measuring probe length
up to 1,400 mm with the following quarterly order quantity:
• DUT-E A5/A10/I — from 500 pcs.;
• DUT-E AF/ 232/485/CAN — from 100 pcs.
** Supplied as DUT-E 232 / 485 models without standard measuring probe. Used together with additional DUT-E sections.
DUT-E fuel level sensors
Operation manual. Version 6.0 8
Configuration of DUT-E AF, DUT-E 232, DUT-E 485 and DUT-E CAN requires
SK DUT-E service kit (should be ordered separately).
ATTENTION: It is strongly recommended to follow strictly the instructions of the present Manual when using, mounting or maintaining DUT-E and SK DUT-E
The Manufacturer guarantees DUT-E compliance with the requirements of technical regulations subject to the conditions of storage, transportation and operation set out in this Manual.
ATTENTION: Manufacturer reserves the right to modify DUT-E specifications that do not lead to a deterioration of the consumer qualities without prior customer notice.
DUT-E fuel level sensors
Operation manual. Version 6.0 9
General information and technical specifications / Purpose of use and application area
1 General information and technical specifications
1.1 Purpose of use and application area
is designed to measure level of liquid fuel and other nonconductive liquids in vehicle and stationary tanks (see Figure 2).
Figure 2 — DUT-E purpose of use
Application area — used in GPS/GLONASS vehicle monitoring and fuel consumption control
systems as additional fuel sensor or as a replacement of standard (factory built-in) fuel level sensors (see Figure 3).
a) in GPS/GLONASS vehicle monitoring and fuel consumption control system
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Operation manual. Version 6.0 10
General information and technical specifications / Purpose of use and application area
b) in S6 telematics bus *
Figure 3 — DUT-E application
DUT-E is installed into a fuel tank of a vehicle. The sensor measures fuel level in the tank and generates an output signal to forward it to a vehicle tracking device.
Tracking device records and processes the sensor data for further transmission to the telematics server. Server software processes and analyzes the received data to generate analytical reports for a selected period of time.
The user gets the reports on vehicle
fuel tank volume and consumption (see Figure 4).
Figure 4 — Example of DUT-E data analysis
* DUT-E CAN only.
DUT-E fuel level sensors
Operation manual. Version 6.0 11
General information and technical specifications / Purpose of use and application area
Using J1939 output protocol makes possible DUT-E CAN fuel level sensors operation as a part of telematics bus together with DFM CAN fuel flow meters and other factory-built or additional equipment (see Figure 3b).
With DUT-E CAN in S6 telematics bus it is possible to obtain real-time monitoring of:
• fuel tank level and volume;
• total volume of fuel in up to 8 tanks and a separate volume value for each of the tanks;
• fuel temperature;
• sensor specification data (passport);
• presence of water in fuel;
• sensor malfunctions.
Tracking device can receive data from up to 8 DUT-E CAN sensors and up to 4 DFM CAN fuel flow meters via a single CAN interface port. This feature is very important for complicated applications like special utility vehicles as it provides ability to receive fuel monitoring data from vehicle itself as well as from special equipment mounted on the vehicle.
DUT-E application as a part of vehicle telematics system allows operator to:
• receive accurate information on the current amount of fuel in the tank;
• determine exact refueling amount;
• reveal fuel theft facts;
• monitor fuel consumption rate.
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Operation manual. Version 6.0 12
General information and technical specifications / Exterior view and delivery set
1.2 Exterior view and delivery set
DUT-E delivery set includes (see figure 5):
8 9 10
7
2
6
1
Figure 5 — DUT-E delivery set
1 - DUT-E fuel level sensor
2 - specification
3 - connection cable* (7.5 m)
4 - bottom stop
5 - mud filter
6 - rubber gasket
7 - sealing rubber ring for the plastic mounting plate
8 - plastic mounting plate
9 - bolt
10 - self-tapping screw
11 - plastic seal
12 - sealing cord
– 1 pc.;
– 1 pc.;
– 1 pc.;
– 1 pc.;
– 1 pc.;
– 2 pcs. **;
– 2 pcs. **;
– 1 pc.;
– 5 pcs.;
– 5 pcs.;
– 2 pcs.;
– 2 pcs.
* ordered separately for DUT-E CAN.
** 1 pc. is used for initial DUT-E mounting and 1 pc. as a spare part.
12
DUT-E fuel level sensors
Operation manual. Version 6.0 13
4
5
11
3
General information and technical specifications / Unit structure and operation principle
1.3 Unit structure and operation principle
3
DUT-E fuel level sensor (see Figure 6) consists of a measuring probe 1, fuel level sensor head with PCB (printed circuit board) inside 2, and interface cable 3 with connector plug 4.
3
2
4
2
DUT-E 232 Base
DUT-E 485 Base
2
2
3
1
4
4
DUT-E A5
DUT-E A10
DUT-E I
3
DUT-E CAN
1
4
DUT-E AF
DUT-E 232
DUT-E 485
1
Figure 6 — DUT-E structure
DUT-E fuel level sensors
Operation manual. Version 6.0 14
General information and technical specifications / Unit structure and operation principle
DUT-E operation principle is based on condenser capacitance measurement, where measuring probe pipes are used as capacitor plates. Electric capacitance changes depending on measuring probe immersion depth in the fuel which is dielectric liquid. The sensor analyzes current value of electric capacitance and then generates an appropriate output signal.
Fuel level translation is carried out in accordance with calibration table. To create the table it is necessary to calibrate the fuel tank. This procedure is a sequence of fixed refueling portions from empty to full tank. During calibration the value of DUT-E output signal is established depending on fuel amount in particular tank (see DUT-E fuel level sensor installation video for details).
DUT-E output signal specification according to Clauses 1.4.2
When using DUT-E AF, DUT-E A5, DUT-E A10 and DUT-E I fuel level sensors, calculation of fuel amount is carried out in a registration unit such as a GPS tracker or on the server using vehicle monitoring system software.
DUT-E 232, DUT-E 485, and DUT-E CAN fuel level sensors can calculate current fuel amount independently in accordance with calibration table recorded in the sensor internal memory with
SK DUT-E service kit.
DUT-E fuel level sensors
Operation manual. Version 6.0 15
General information and technical specifications / Technical specifications / Main specifications
1.4 Technical specifications
DUT-E
is powered by on-board power supply of the vehicle where it is installed.
DUT-E can be used in the conditions of temperate and cold climates.
For resistance to mechanical impact DUT-E is shake- and shockproof.
1.4.1 Main specifications
DUT-E main specifications are shown in Chart 1.
Chart 1 — DUT-E main specifications
Parameter, measuring unit
Operating principle
Relative measuring error (to the length of the measuring part), %, not more than
Power supply voltage range, V
Consumption current at power supply voltage of
12 V, mA, not more than
Consumption current at power supply voltage of
24 V, mA, not more than
Availability time after power-up, seconds, not more than
Temperature range, °C
Value capacitive
±1 from 10 to 50
50*
25*
10 from -40 to +85
Ingress protection rating IP55/57
Electromagnetic compatibility
• ESD Protection, severity level II
(GOST 30378,
GOST R 50607);
• electromagnetic interference protection, severity level IV
(STB ISO 7637-2,
GOST 28751).
* For DUT-E CAN consumption current at the power supply voltage of 12 V – not more than
150 mA, and at the power supply voltage of 24 V — not more than 75 mA.
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Operation manual. Version 6.0 16
1.4.2 Specifications of DUT-E AF output signal
DUT-E AF fuel level sensor has an analog and frequency output which can be
configured via K-Line (ISO 9141) interface.
Output signal value does not depend on supply voltage and is linear dependent on the fuel level.
The capacity of analog-digital output signal converter is 12 bit.
DUT-E AF output signal range:
• voltage output — from 1.0 to 9.0 V. The lower limit of the range can be configured from
1.0 V to 8.0V and the upper limit from 2.0 V to 9.0V;
Note — variation of the output voltage of the sensor can be set in both direct and inverse dependence.
• Frequency output — from 500 to 1500 Hz. Frequency output signal has a meander shape with 50% duty ratio. High level voltage value equals to (10 ) minus 0.5 V. Low
-1,0 level voltage value is not more than 0.5 V.
Depending on settings DUT-E AF output signal value can stand for:
•
• fuel level in the tank (mm); fuel volume (L);
• total fuel volume (L) of up to eight tanks.
DUT-E AF output signal correspondent to fuel volume is generated according to calibration chart of the fuel tank which is stored in the sensor’s memory.
Input resistance of the device DUT-E AF is connected to in frequency output mode should not be less than 10 kOhm;
In voltage output mode output resistance value is not more than 5 kOhm for low level and not more than 50 kOhm for high level.
DUT-E fuel level sensors
Operation manual. Version 6.0 17
General information and technical specifications / Technical specifications /
Specifications of DUT-E A5/A10/I output signal
1.4.3 Specifications of DUT-E A5/A10/I output signal
Output signal voltage values (for DUT-E A5 and DUT-E A10) and current values (for DUT-E I) are linear dependent on fuel level in the tank.
Output signal value does not depend on supply voltage value.
Input resistance of the device DUT-E A5 and DUT-E A10 I is connected to should not be less than 10 kOhm.
Input resistance of the device DUT-E I is connected to should not be more than 260 Ohm for
12 V power supply voltage and should not be more than 800 Ohm for 24 V power supply voltage.
For DUT-E I correct performance the difference between minimum on-board power supply voltage and load voltage for the full tank should not be less than 5 V.
See Chart 2 for DUT-E A5, DUT-E A10 and DUT-E I output signal specifications.
Chart 2 — DUT-E A5, DUT-E A10 and DUT-E I output signal specifications
DUT-E model
DUT-E A5
DUT-E A10
DUT-E I
Fuel tank status
Empty
Full
Empty
Full
Empty
Full
Voltage, V for nominal probe length
1.5 for 30% cut probe
0.9
4.5 3.7
2.5
9.0
-
-
1.0
5.6
-
-
Current, mA for nominal probe length
-
-
-
-
6.7
20.0 for 30% cut probe
-
-
-
-
4.0
16.4
DUT-E fuel level sensors
Operation manual. Version 6.0 18
1.4.4 Specifications of DUT-E 232 and DUT-E 485 output signal
Specifications of DUT-E 232 and DUT-E 485 output signal correspond to the specifications of
RS-232 and RS-485 interfaces.
Depending on settings output value of DUT-E 232 and DUT-E 485 can stand for:
• standard (normalized) units, from 0 to 1000 (0 – empty tank, 1000 – full tank);
• fuel level in the tank (mm);
• fuel volume (L);
• percentage of full tank capacity (%).
DUT-E sensor sends data on current temperature as well (value is measured with the temperature sensor located on the PCB).
DUT-E 232 and DUT-E 485 data transfer is carried out according to
DUT-E COM Protocol .
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Operation manual. Version 6.0 19
General information and technical specifications / Technical specifications /
Specifications of DUT-E CAN output signal
1.4.5 Specifications of DUT-E CAN output signal
DUT-E CAN output signal specifications correspond to specifications of telematics bus, designed by Technoton to integrate vehicle tracking systems with elements of the vehicle electrical system which represent the system of cables, interfaces, and protocols.
Data transfer to S6 bus is carried out via CAN 2.0B interface (ISO 11898-1:2003). Data
transfer protocol satisfies the requirements of SAE J1939-73 standard.
DUT-E CAN data can be transferred to S6 bus automatically (default mode) and upon request.
S6 bus allows connecting of up to eight DUT-E CAN fuel level sensors. To identify them in the bus decimal addresses from 101 to 108 are used.
DUT-E CAN setup in S6 bus is carried out via K-Line (ISO 9141) interface.
DUT-E CAN generates and transfers messages according to Chart 3.
Chart 3 —messages of DUT-E CAN data transfer protocol
Message format Brief message transcript
PGN 62982
PGN 62995
PGN 63008
PGN 65226
PGN 65276
Fuel level and fuel volume in the tank
DUT-E CAN specification details (passport)
DUT-E CAN status
Active malfunctions (DTCs) DUT-E CAN
Dashboard
PGN 65279 Operator indicators
* See Annex C for detailed description.
DUT-E CAN data is transmitted according to DUT-E CAN protocol .
DUT-E fuel level sensors
Operation manual. Version 6.0 20
General information and technical specifications / Technical specifications /
DUT-E and tracking devices compatibility
1.4.6 DUT-E and tracking devices compatibility
Technoton Technoton guarantees complete compatibility and joint accuracy of DUT-E
A5/AF with CKPT 45, CKPT 25, and CKPT 31 tracking devices and BSKD T-60 onboard diagnostics and monitoring system.
Technoton regularly conducts tests for compatibility and joint accuracy of DUT-E with different tracking devices of popular brands. Chart 4 shows tracking devices models compatible with
DUT-E providing accuracy error of joint fuel consumption measurement of not more than ±1 %.
Chart 4 — Compatible vehicle tracking devices
Tracking device
Analytical software Model
Brand Trade Mark Model
CKPT
GALILEOSKY
Avtograf
Teltonika
Ruptela
MapOn
NaviFleet
Locarus
31
25
45
GPS
GSM (GLONASS)
GSM+
GSM+
FM1100
FM4200
FM5300
FM-Pro3
FM-Pro3
GBOX6
GBOX6
ET100
ET100
ET100
702R
702X
702S
ORF-MONITOR
Wialon
Avtograf software
TAVL.NET
TAVL.NET
TAVL.NET
Trust-Track web server
MapOn web server
NaviFleet
LocarusInformer
DUT-E A5/AF
DUT-E 232
DUT-E 485
DUT-E A5/A10/AF
DUT-E 485
DUT-E CAN
DUT-E A5/A10/AF
DUT-E 232
DUT-E A5/A10/AF
DUT-E 232
DUT-E A5/AF
DUT-E 232
DUT-E A5/A10/AF
DUT-E 232
DUT-E 485
DUT-E A5/A10/AF
DUT-E 485
DUT-E AF
DUT-E fuel level sensors
Operation manual. Version 6.0 21
General information and technical specifications / Technical specifications /
DUT-E and tracking devices compatibility
Chart 4 continued
Brand
Tracking device
Trade Mark
Naviset
Model
GT-10
Analytical software
GPS-Trace Orange
Model
DUT-E A5/A10/AF
Queclink
Signal
IRZ–Lira
GV200
S-2117
ST 270
Network Stuff DUT-E 232 http://cybermonitor.ru/ DUT-E 485
Scout Explorer v3.0 DUT-E A5/A10/AF
Helios Adv+ AMP10353 eInstall DUT-E A5/A10/AF
MT-530 Scout Explorer v3.0 DUT-E A5/A10/AF
SKOUT
BCE
VOYAGER
GLOSAV
ORBITA
Atrack
GPS
Watchman
SkyWave
SL-C
Simbiotecha
MT-600 GP PRO DUT-E A5/A10/AF
Scout Explorer v3.1
MT-600 GP PRO
Fm Light
Fm Blue
2
2
BK11-02
Navigator.01
Navigator.01
AT1E
GPS
Watchman
IDP 690
Wialon
RITM-PCN
GLOSAV
DUT-E 485
DUT-E A5/A10/AF
DUT-E A5/A10/AF
DUT-E AF
DUT-E 485
DUT-E 232
Wialon
DUT-E 485
ATrack Server Tool
GPS Watchman
Monitoring and logistics software
Wialon
DUT-E 232
DUT-E A5/A10/AF
DUT-E 485 iSat iSat
LLS software module for iSat tracking device
DUT-E 232
DUT-E 485
GATE-FM 200 Monitoring server software
“Fuel monitoring system”
GATE-FM 200 www.tracking.lt
DUT-E A5/AF
DUT-E A5/AF
Relevant information on the compatibility of specific models of tracking devices and DUT-E fuel level sensors and recommendations for their connection and setup can be found at http://www.jv-technoton.com/
DUT-E fuel level sensors
Operation manual. Version 6.0 22
General information and technical specifications / Technical specifications /
DUT-E explosion-proof modification
1.4.7 DUT-E explosion-proof modification
Special explosion-proof Ex version of DUT-E fuel level sensors is designed for use in hazardous areas.
An explosion-proof sensor has a special explosion-proof marking which identifies the following:
• explosion protection class — 1ExibIIBT6;
• type of explosion protection — “i” spark-safe circuit.
To meet the requirements for spark-safe circuit, explosion-proof DUT-E electrical connection has to be carried out by an external power and spark protection supply (purchased separately).
Spark-safe circuit must match the parameters specified in Chart 5.
Chart 5 — Spark-safe circuit parameters
Parameter, unit of measurement
Maximum input voltage, V
Maximum input current Ii, mA
Maximum internal capacitance Ci, μF
Maximum internal inductance Li, mH
Value
10
200
15.0
1.188
DUT-E fuel level sensors
Operation manual. Version 6.0 23
General information and technical specifications / Technical specifications / Overall dimensions
1.4.8 Overall dimensions
See Figure 7 for DUT-E overall dimensions 7.
Figure 7 — DUT-E overall dimensions
* Nominal measuring probe length.
DUT-E fuel level sensors
Operation manual. Version 6.0 24
DUT-E installation / Exterior inspection prior to works start
2 DUT-E installation
For DUT-E correct operation its mounting and configuration should be carried out by certified specialists who have passed corporate technical training .
ATTENTION: Strictly follow safety rules of automobile repair works as well as local safety rules of the customer company when mounting DUT-E.
DUT-E can be mounted either into the flange of factory mounted float sensor * or into a specially drilled hole of the fuel tank.
This chapter contains basic recommendations on DUT-E installation.
Check out DUT-E fuel level sensor installation video.
2.1 Exterior inspection prior to works start
It is necessary to conduct DUT-E exterior inspection for the presence of the possible defects arisen during transportation, storage or careless use.
Contact the product supplier if there any defects.
* Study carefully the layout of the mounting bores for a factory mounted fuel sensor and compare it with the drawing of bores for a DUT-E mounting plate
DUT-E fuel level sensors
Operation manual. Version 6.0 25
DUT-E installation / Standard fuel sensor replacement
2.2 Standard fuel sensor replacement
ATTENTION: If the standard fuel sensor is not located in the geometrical center of the tank, it is not recommended to replace it with DUT-E. DUT-E installation far from the geometrical center of the tank will lead to significant fluctuations in fuel level readings.
Dismount the standard sensor and clean the mounting area before DUT-E mounting.
DUT-E delivery set contains a mounting plate. The layout of the bores for the mounting plate fastening is shown in Figure 10.
The holes of the mounting plate and rubber gasket must be aligned with the bores in the tank.
M5x16 bolts can be used for installation; they are included into the DUT-E package. Bolt or
screw heads must be completely sunk in the mounting plate (see Figure 8).
Figure 8 — Mounting plate screwed to the tank
Preorder correspondent mounting plate to replace the standard sensor with SAE 5 bolt bores layout.
DUT-E fuel level sensors
Operation manual. Version 6.0 26
DUT-E installation / Installation into a special hole
2.3 Installation into a special hole
WARNING:
1) Before drilling a bore in a fuel tank, the tank must be emptied, dismounted (if necessary) and dried or filled with water.
2) Before drilling, make sure that there are no bulkheads that interfere DUT-E installation.
3) Eliminate contact of DUT-E measuring probe with the bar of the standard float fuel sensor.
DUT-E installation procedure:
1) Determine installation location. Geometrical center of the fuel tank is recommended
(see Figure 9). This will reduce measurement errors caused by fuel level deviation during driving.
Standard fuel sensor DUT-E in the geometrical center of the tank
Figure 9 — Recommended location for a DUT-E installation
2) Mark and drill bores according to bores layout for DUT-E mounting plate (see Figure 10).
ATTENTION: The mounting plate can be installed only in one position on the bores prepared! Before marking and drilling, examine the place where you plan to fix the mounting plate because sealing holes should be accessible.
DUT-E fuel level sensors
Operation manual. Version 6.0 27
DUT-E installation / Installation into a special hole
Figure 10 — Bores layout for DUT-E mounting plate fastening
3) Put the rubber gasket and the mounting plate on the prepared bores, after that fix the plate with M5x16 bolts or with 3.9x25 self-tapping screws from the MK DUT-E mounting kit
(see Figure 11).
ATTENTION: When fixing the mounting plate to the tank, make sure that the bolt or screw heads are not skewed and completely sunk in the plate in order to provide electrical isolation between the tank and DUT-E.
DUT-E fuel level sensors
Operation manual. Version 6.0 28
DUT-E installation / Installation into a special hole
Figure 11 — Mounting plate fastening
RECOMMENDATION: For a further easier sealing of DUT-E sensor pass the sealing cord through the sealing hole of the plate prior to fastening the plate to the tank!
DUT-E fuel level sensors
Operation manual. Version 6.0 29
DUT-E installation / Probe cutting according to tank depth
2.4 Probe cutting according to tank depth
ATTENTION: DUT-E AF/232/485/CAN allow cut off up to any required probe
length with mandatory further calibration.
DUT-E A5/A10/I allow cut off up to 30 % of the initial length of the measuring probe with no further calibration.
DUT-E cutting procedure instructions:
1) Measure the depth of the tank from mounting plate to the bottom;
WARNING: It is required to leave a 25 mm gap between the edge of the measuring probe and the tank bottom to:
• provide at least 10mm operation area for bottom spring stopper (if the bottom spring is fixed in full loading position the bayonet mounting plate can get damaged);
• avoid the short circuit of the measuring probe tubes with conductive mud or water at the tank bottom.
2) Cut off DUT-E probe so that the edge of the probe is in 25 mm above the bottom of the tank;
Figure 12 — DUT-E measuring probe cutting
RECOMMENDATION: Cut DUT-E probe with a metal hacksaw. Carefully clean the edge and wash the tubes with clean fuel (see Figure 12).
3) DUT-E AF/232/485/CAN require min/max calibration with SK DUT-E service kit after
DUT-E fuel level sensors
Operation manual. Version 6.0 30
DUT-E installation / Length extension
2.5 Length extension
Length extension is performed by fastening KDC additional sections to the measuring probe of
DUT-E sensor (see Figure 13 and DUT-E Length extension with KDC video).
DUT-E AF/232/485/CAN can be extended up to 6000 mm length.
DUT-E A5/A10/I extension is possible only up to the initial size of particular sensor
(if been cut).
Length extension option significantly decreases expenses on storage and transportation. a) exterior view b) fastening order c) fastening order of two sections
Figure 13 — DUT-E additional section
DUT-E additional sections can be cut to necessary size. Follow instructions of clause 2.4
cutting the sections.
Model range of DUT-E additional sections includes: KDC 250, KDC 500 and
KDC 1000 with lengths of 250, 500 and 1000 mm respectively.
DUT-E fuel level sensors
Operation manual. Version 6.0 31
2.6 Mounting
To mount DUT-E sensor lay the sealing ring accurately into the groove of mounting plate, then put the sensor into the opening, press firmly and lock by turning clockwise
(see Figure 14).
RECOMMENDATION: It is recommended to put some oil or fuel on the sealing ring of the mounting plate to prevent its deformation during DUT-E mounting.
The mounting should be carried out so that both sensor and mounting plate sealing holes would match one another after locking the DUT-E.
Figure 14 — DUT-E mounting
DUT-E fuel level sensors
Operation manual. Version 6.0 32
DUT-E installation / Electrical connection
2.7 Electrical connection
ATTENTION:
1) Before mounting and connecting DUT-E switch off power supply of the vehicle electrical circuits. To do this switch off the battery switch or release the terminals of the wires connected to the battery.
2) It is recommended to use fuses (ordered separately) when connecting DUT-E power supply (see Figure 16a). Nominal fuse current is not more than 2 A.
3) DUT-E power supply “+” and Ground “-” wires should be connected to the same points of vehicle electric circuit as correspondent wires of the tracking device (data logger).
4) Prior to electrical connection of the sensor pay special attention to Checking vehicle chassis ground. Resistance between any point of vehicle chassis and “-” terminal of the battery or between terminals of the chassis ground switch should not exceed
1 Ohm.
5) It is strongly recommended to lay DUT-E connection cable together with the standard vehicle wiring with the mandatory tie-wrap fixing of every 50 cm
(see Figure 15).
DUT-E body is electrically connected to Ground “-” (brown wire of the connection cable).
Electrical isolation between the DUT-E body and the fuel tank is provided by the mounting plate made of dielectric plastic material.
Tie-wraps
DUT-E connection cable
Figure 15 — DUT-E connection cable laying
Terminals are recommended for electrical connection of power supply wires (see Figure 16b). and quick splice connectors for output signal wire connection (see Figure 16c). a) fuse b) terminals c) connectors
Figure 16 — DUT-E connection accessories
DUT-E fuel level sensors
Operation manual. Version 6.0 33
DUT-E installation / Electrical connection / Electrical connection of DUT-E AF
2.7.1 Electrical connection of DUT-E AF
DUT-E AF
electrical connection is made according to pinout of the connector and interface cable wires description. See Figure 17 and Chart 6 for details
.
Figure 17 — DUT-E AF interface cable connector pinout
Chart 6 — DUT-E AF interface cable wires assignment
Pin number
Wire
marking
Wire color*
1 VBAT Orange
2 GND Brown
3 KLIN Black
4 T034 White
* Manufacturer reserves the right to modify wire colors
Assignment
Power supply “+”
Ground
K-Line (ISO 14230)
DUT-E fuel level sensors
Operation manual. Version 6.0 34
DUT-E installation / Electrical connection / Electrical connection of DUT-E A5/A10/I
2.7.2 Electrical connection of DUT-E A5/A10/I
DUT-E A5/A10/I electrical connection is made according to pinout of the connector and interface cable wires description. See Figure 18 and Chart 7 for details.
Figure 18 — DUT-E A5/A10/I interface cable connector pinout
Chart 7 — DUT-E A5/A10/I interface cable wires assignment
Pin number
Wire
marking
Wire color* Assignment
1 T701/T034 White
2
3
GND/T734
VBAT
Brown
Orange
* Manufacturer reserves the right to modify wire colors
Ground
Power supply “+”
DUT-E fuel level sensors
Operation manual. Version 6.0 35
DUT-E installation / Electrical connection / Electrical connection of DUT-E 232/485
2.7.3 Electrical connection of DUT-E 232/485
DUT-E 232 and DUT-E 485 electrical connection is made according to pinout of the connector and interface cable wires description. See Figure 19 and Chart 8 for details.
Figure 19 — DUT-E 232/485 interface cable connector pinout
Chart 8 — DUT-E 232/485 interface cable wires assignment
Pin number
Wire
marking
Wire color*
1 VBAT Orange
2 GND Brown
3 232R/485A White
4 232T/485B Red
* Manufacturer reserves the right to modify wire colors
Assignment
Power supply “+”
Ground
Received data (RS-232)
Data exchange (RS-485)
Transmitted data (RS-232)
Data exchange (RS-485)
DUT-E fuel level sensors
Operation manual. Version 6.0 36
DUT-E installation / Electrical connection / Electrical connection of DUT-E CAN
2.7.4 Electrical connection of DUT-E CAN
DUT-E CAN electrical connection is made according to pinout of the connector and interface cable wires description. See Figure 20 and Chart 9 for details.
See Annex B (Figures B1-B4) for DUT-E CAN connection options indicating additional cables to
be ordered for particular connection type.
Figure 20 — DUT-E CAN interface cable connector pinout
Chart 9 — DUT-E CAN interface cable wires assignment
Pin number
1
2
3
4
5
Wire
marking
VBAT
GND
CANH
CANL
KLIN
Wire color*
Orange
Brown
Blue
White
Black
* Manufacturer reserves the right to modify wire colors
Assignment
Power supply “+”
Ground
CAN-High (SAE J1939)
CAN-Low (SAE J1939)
K-Line (ISO 9141)
RECOMMENDATION: Manufacturer reserves the right to modify wire colors. Primarily check wire marking when connecting DUT-E sensors.
DUT-E fuel level sensors
Operation manual. Version 6.0 37
DUT-E installation / Monitoring of two and more tanks / DUT-E 232 readings totalizing
2.8 Monitoring of two and more tanks
2.8.1 DUT-E 232 readings totalizing
DUT-E SUM 232 summator designed by Technoton is used together with DUT-E 232 sensors on vehicles with two and more fuel tanks for measuring total amount of fuel (see Figure 21).
ATTENTION:
1) DUT-E SUM 232 summator operates only with DUT-E 232 sensors with firmware version 3.0 and higher.
2) Fuel tank calibration table should be recorded into the internal memory of each
Figure 21 — DUT-E SUM 232
DUT-E SUM 232 output message contains total fuel volume (in liters) as a sum of the values measured by sensors connected to its IN and IN/OUT inputs.
Electrical connection of summators is carried out according to the diagrams provided in Figure
22 and in compliance with wire assignment provided in Chart 10.
Two DUT-E 232 sensors are connected to the single tracking device according to Figure 22a.
If there are three or more fuel tanks to be measured with DUT-E 232 sensors, cascade connection can be used according to Figure 22b.
Connectors are recommended for signal wires connection (see 2.7
DUT-E fuel level sensors
Operation manual. Version 6.0 38
DUT-E installation / Monitoring of two and more tanks / DUT-E 232 readings totalizing
Chart 10 —DUT-E SUM 232 wires assignment
Wire number Wire marking Wire color*
1 VBAT Orange
2 GND Brown
3 232R White
4 232T Red
* The manufacturer reserves the right to change wire colors.
Assignment
Power supply “+”
Ground
Received data
(RS-232)
Transmitted data
(RS-232)
To get correct values DUT-E 232 sensors should be configured with Service DUT-E utility
according to the following instructions (see 3.10.4
1) For data output in upon request mode the following parameters must be applied for all the sensors:
• “Automatic transmission mode” switched Off (Operation modes module);
• “Output message” selected as Volume (L) (Output message module).
2) For data output in automatic mode the following parameters must be applied:
• for all the sensors — “Output message” ” selected as Volume (L) (Output message module);
•
• sensor N
1
—“Automatic transmission mode” selected as HEX, “Message Interval
(sec)” value is 1 (Operation modes module); sensors N
2
… N
(n-1)
—“Automatic transmission mode” switched Off (Operation
modes module);
•
sensor N n
(the last one) — “Automatic transmission mode” set to
HEX\ASCII\ASCII EXT, “Message Interval (sec)” set any required by the tracking device value (Operation modes module).
Note — for sensor N n
(the last one) at least 8 seconds message interval is recommended.
DUT-E fuel level sensors
Operation manual. Version 6.0 39
DUT-E installation / Monitoring of two and more tanks / DUT-E 232 readings totalizing
Figure 22 — DUT-E SUM 232 connection schemes
DUT-E fuel level sensors
Operation manual. Version 6.0 40
DUT-E installation / Monitoring of two and more tanks / DUT-E AF readings totalizing
2.8.2 DUT-E AF readings totalizing
DUT-E SUM AF summator designed by Technoton is used together with DUT-E AF sensors on vehicles with two and more fuel tanks for measuring total amount of fuel (see Figure 23).
ATTENTION:
1) DUT-E SUM AF summator operates only with DUT-E AF sensors with firmware version 3.5 and higher.
2) Fuel tank calibration table should be recorded into the internal memory of each
3) Readings can be totalized both analog (voltage) and frequency output signal types of DUT-E AF.
Figure 23 — DUT-E SUM AF
DUT-E SUM AF output message contains total fuel volume (in liters) as a sum of the values measured by sensors connected to its IN and IN/OUT inputs.
Electrical connection of summators is carried out according to the diagrams provided in Figure
24 and in compliance with wire assignment provided in Chart 11.
Two DUT-E AF sensors are connected to the single tracking device according to Figure 24a.
If there are three or more fuel tanks to be measured with DUT-E AF sensors, cascade connection can be used according to Figure 24b.
Connectors are recommended for signal wires connection (see 2.7
DUT-E fuel level sensors
Operation manual. Version 6.0 41
DUT-E installation / Monitoring of two and more tanks / DUT-E AF readings totalizing
Figure 24 — DUT-E SUM AF connection schemes
DUT-E fuel level sensors
Operation manual. Version 6.0 42
DUT-E installation / Monitoring of two and more tanks / DUT-E AF readings totalizing
Chart 11 — DUT-E SUM AF wires assignment
Wire number Wire marking Wire color* Assignment
1 VBAT Orange Power supply “+”
2 GND Brown Ground
3 KLIN Black K-Line (ISO 9141)
* The manufacturer reserves the right to change wire colors.
To get correct values DUT-E AF Analog output should be configured with Service DUT-E utility
(version 3.22 and higher). Configuration instructions (see 3.10.4
• when totalizing readings of DUT-E AF in analog output mode select U output signal type for all sensors. Insert minimum (U min
, V) and maximum (U into correspondent fields. max
, V) signal values
ATTENTION: When totalizing readings of DUT-E AF in frequency output mode select F parameter value for N n
sensor from the Output type drop-down list. Select U for
N
1
…N n-1
sensors.
• select the highest address for N n
sensor at Settings-Operation modes module.
Select consecutive network addresses for N
1
…N n-1 sensors without missing addresses for the best and fastest totalizing performance (see Figure 24).
• select Sum parameter value for N n
sensor from the second drop-down list. Any type
(Level or Volume) can be set for N
1
…N n-1
sensors.
• exit Service DUT-E since sensor is configured because the utility is blocking data exchange between DUT-E AF.
DUT-E fuel level sensors
Operation manual. Version 6.0 43
DUT-E installation / Monitoring of two and more tanks / DUT-E CAN readings totalizing
2.8.3 DUT-E CAN readings totalizing
ATTENTION:
1) Up to 8 DUT-E CAN sensors can be connected to S6 telematics bus. For their identification decimal addresses from 101 to 108 are used.
2) Fuel tank calibration table should be stored in the internal memory of each DUT-E
CAN connected to S6 bus (see 3.10.7
1) MasterCAN C 232/485 and MasterCAN V-GATE should be used together with DUT-E CAN sensors for monitoring of total volume of several fuel tanks.
See
Annex D (Figure D.1) for connection scheme of MasterCAN and DUT-E CAN and order
codes of required cables.
Check out MasterCAN Operation Manual for detailed information on vehicle data interfaces
MasterCAN C 232/485 and MasterCAN V-GATE.
2) DUT-E CAN sensors with 4.6 and higher can be used for obtaining data on total fuel volume of several tanks under CAN 2.0B interface.
See Annex B (Figure B.1 and B.4) for connection scheme of DUT-E CAN and order codes of
required cables.
To get correct values DUT-E CAN should be configured with Service DUT-E utility (version 3.25
and higher). Configuration instructions (see 3.10.4) :
• select the highest address for N n
sensor at Settings-Operation modes module.
For the correct and fast data transfer from sensor to sensor network addresses N
1
• to N n-1 should be consequent. set Master for N n
sensor in Summator drop-down list.
• set Slave status for N
1
to N n-1
in Summator drop-down list.
• set Off in drop-down list if there no need for totalizing
• shut down Service DUT-E since configuration is made because the further operation of the utility blocks data exchange between DUT-E CAN.
DUT-E fuel level sensors
Operation manual. Version 6.0 44
2.9 Sealing
It is required to seal the sensor and cable connector with sealing cords and disposable plastic seals to prevent fuel thefts or unauthorized interference into DUT-E operation (see Figure 25).
Seals and cord are included into DUT-E delivery set.
ATTENTION: Security sealing of DUT-E AF, DUT-E 232, DUT-E 485 and DUT-E CAN cable connector should be carried out after the configuration and calibration are
To seal the sensor put the sealing cord through the special holes of the mounting plate and
DUT-E body. Then put the ends of the cord through the holes in the center of the plastic seal body. Latching the seal will lock the cord. Seal removal will be impossible without its damaging.
Figure 25 — Plastic seal* and sealing cord
WARNING: Sealing rope should not touch the fuel tank body!
* Design of the seal supplied within the delivery set can differ from the one displayed in
Figure 25.
DUT-E fuel level sensors
Operation manual. Version 6.0 45
Configuration with SK DUT-E service kit / SK DUT-E application
3 Configuration with SK DUT-E service kit
Minimum/maximum measurement level calibration is required for correct operation of
DUT-E AF/232/485/CAN as well as configuration according to specific operating conditions and requirements of tracking devices / data loggers.
Calibration and configuration is carried out with SK DUT-E service kit (ordered separately).
ATTENTION: DUT-E A5/A10/I do not require any calibration and configuration.
Check out DUT-E installation video for configuration instance.
3.1 SK DUT-E application
SK DUT-E service kit is designed for configuration of
DUT-E AF/232/485/CAN models and communication between sensor and PC.
Service DUT-E utility is required to be installed on PC to operate SK DUT-E . The installation disk of the utility is included into SK DUT-E delivery set.
Up-to-date Service DUT-E version of the utility can be downloaded from http://www.jv-technoton.com/ .
Service DUT-E functions:
• checking and modifying sensor settings;
• min/max calibration;
• fuel tank calibration;
• saving sensor configuration profile to PC;
• upload previously saved configuration profile from PC to sensor;
• monitor sensor output data;
• run sensor diagnostics;
• update sensor firmware.
DUT-E fuel level sensors
Operation manual. Version 6.0 46
Configuration with SK DUT-E service kit / Hardware requirements
3.2 Hardware requirements
To run Service DUT-E utility IBM-compatible PC is required (desktop or laptop):
• CPU - Intel or AMD with a minimum clock speed of 800 MHz;
• RAM - 256 MB (recommended 512 MB or more);
• USB port;
• CD-ROM / DVD-ROM;
• operating system - Windows XP/Windows Vista/Windows 7/Windows 8.
DUT-E fuel level sensors
Operation manual. Version 6.0 47
Configuration with SK DUT-E service kit / Service kit components / Exterior view and delivery set
2
3
4
3.3 Service kit components
3.3.1 Exterior view and delivery set
SK DUT-E delivery set includes (see figure 26):
1
5
7
8
9
6
10
1 - universal service adapter;
2 - license certificate of Service DUT-E utility;
3 - CD Driver USB;
4 - CD Service DUT-E utility;
5 - SK DUT-E specification;
6 - USB A-B cable;
7 - RS-485 service cable;
8 - RS-232 service cable;
9
10
- A10 service cable;
- CAN service cable.
Figure 26 — SK DUT-E delivery set
DUT-E fuel level sensors
Operation manual. Version 6.0 48
Configuration with SK DUT-E service kit / Service kit components / Universal service adapter
3.3.2 Universal service adapter
Universal service adapter (hereinafter adapter) is designed to transmit data between
DUT-E sensors and PC.
See Figure 27 for adapter exterior view.
1 2 3 4 5
1 – RS-232/ISO14230/RS-485 socket for DUT-E connection;
2 – TX yellow LED indicator of data transmitted to DUT-E;
3 – RX green LED indicator of data received from DUT-E;
4 – ON red LED indicator of power supply;
5 – USB B port for PC connection.
Figure 27 — Adapter exterior view
DUT-E fuel level sensors
Operation manual. Version 6.0 49
Configuration with SK DUT-E service kit / Service kit components / USB A-B Cable
3.3.3 USB A-B Cable
USB A-B cable is used for connection of PC and adapter (see Figure 28)
USB A USB B
Figure 28 — USB A-B cable connectors
DUT-E fuel level sensors
Operation manual. Version 6.0 50
Configuration with SK DUT-E service kit / Service kit components / RS-485 service cable
3.3.4 RS-485 service cable
RS-485 service cable used to connect adapter to DUT-E 485.
See Chart 12 for pinout of RS-485 service cable connectors.
Chart 12 — Pinout of RS-485 service cable connectors
Wire
View Pin No
Marking Color
Signal
Assignment Type
6 GND Brown Ground -
7 GND
10
11
14
15
1
2
3
4
485B
SEL1
VBAT
485A
VBAT
GND
485A
485B
Brown
Red
Brown
Orange
White
Orange
Brown
White
Red
Ground -
Transmitted data
Serial,
RS-485 interface
RS-4
85 Selection
Discrete
Power supply
Received data
Power supply
Analog,
Voltage
0…50 V
Serial,
RS-485 interface
Analog,
Voltage
0…50 V
Ground -
Received data
Transmitted data
Serial,
RS-485
interface
Serial,
RS-485 interface
DUT-E fuel level sensors
Operation manual. Version 6.0 51
Configuration with SK DUT-E service kit / Service kit components / RS-232 service cable
3.3.5 RS-232 service cable
RS-232 service cable used to connect adapter to DUT-E 232.
See Chart 13 for pinout of RS-232 service cable connectors.
Chart 13 — Pinout of RS-232 service cable connectors
View Pin No
4
5
6
14
1
2
3
4
Marking
232Т
232R
GND
VBAT
VBAT
GND
232R
232T
Wire
Color
Red
White
Brown
Orange
Orange
Brown
White
Red
Signal
Assignment Type
Transmitted data
Received data
Serial,
RS-232 interface
Serial,
RS-232 interface
Ground -
Power supply
Power supply
Analog,
Voltage
0…50 V
Analog,
Voltage
0…50 V
Ground -
Received data
Transmitted data
Serial,
RS-232 interface
Serial,
RS-232 interface
DUT-E fuel level sensors
Operation manual. Version 6.0 52
Configuration with SK DUT-E service kit / Service kit components / AF service cable
3.3.6 AF service cable
AF service cable used to connect adapter to DUT-E AF.
See Chart 14 for pinout of AF service cable connectors.
Chart 14 — Pinout of AF service cable connectors
View Pin No
1
3
6
7
12
1
2
1
2
3
4
Marking
VBAT
KLIN
Wire
Color
Orange
Black
GND
GND
SEL2
VBAT
GND
VBAT
GND
KLIN
T034
Brown
Brown
Brown
Orange
Brown
Orange
Brown
Black
White
Signal
Assignment
Power supply
K-Line
Type
Analog,
Voltage
0…32 V
Serial,
ISO9141 standard
Ground -
Ground -
K-Line selection
Discrete
Power supply
Analog,
Voltage
0…32 V
Ground -
Power supply
Analog,
Voltage
0…32 V
Ground -
K-Line
Fuel level
Serial,
ISO9141 standard
Analog,
Voltage
0…9 V
DUT-E fuel level sensors
Operation manual. Version 6.0 53
Configuration with SK DUT-E service kit / Service kit components / CAN service cable
3.3.7 CAN service cable
CAN service cable used to connect adapter to DUT-E CAN.
See Chart 15 for pinout of CAN service cable connectors.
Chart 15 — Pinout of CAN service cable connectors
Wire
View Pin No
1
3
6
Marking
VBAT
KLIN
GND
Color
Orange
Black
Brown
Signal
Assignment Type
Power supply
K-Line
Analog,
Voltage
0…32 V
Serial,
ISO 9141 standard
Ground -
2
1
2
5
7
12
1
GND
SEL2
VBAT
GND
VBAT
GND
KLIN
Brown
Brown
Orange
Brown
Orange
Brown
Black
Ground -
K-Line
Selection
Discrete
Power supply
Analog,
Voltage
0…32 V
Ground -
Power supply
Analog,
Voltage
0…32 V
Ground -
K-Line
Serial,
ISO 9141 standard
DUT-E fuel level sensors
Operation manual. Version 6.0 54
Configuration with SK DUT-E service kit / Software installation / USB driver installation
3.4 Software installation
The following software should be installed on PC before starting work with SK DUT-E :
• USB driver creating virtual COM port (CD Driver USB);
• Service DUT-E utility (CD Service DUT-E).
3.4.1 USB driver installation
ATTENTION: SK DUT-E will not operate correctly without prior USB driver installation.
Insert CD Driver USB into CD-ROM (DVD-ROM) and run installation file
CP210x_VCP_Win_XP_S2K3_Vista_7.exe.
Welcome to the InstallShield Wizard window will appear (Figure 29)
Figure 29 —Welcome to the InstallShield Wizard window
Click button to start the first leg of USB driver installation. Then just follow installation wizard instructions.
You can see installation status in Setup Status window (see Figure 30).
DUT-E fuel level sensors
Operation manual. Version 6.0 55
Configuration with SK DUT-E service kit / Software installation / USB driver installation
Figure 30 —Setup Status window
When the first leg is finished check Launch the CP210xVCP box in InstallShield Wizard
Complete window (see Figure 31) and click .
Figure 31 — InstallShield Wizard Complete window
Silicon Laboratories CP210x USB to UART Bridge Driver Installer window will appear. Click
and USB driver installation will be continued (see Figure 32).
Figure 32 —Silicon Laboratories CP210x
USB to UART Bridge Driver Installer window
DUT-E fuel level sensors
Operation manual. Version 6.0 56
Configuration with SK DUT-E service kit / Software installation / USB driver installation
Successful installation notification window will appear as soon as installation is finishes
(see Figure 33).
Figure 33 — Successful installation notification window
DUT-E fuel level sensors
Operation manual. Version 6.0 57
Configuration with SK DUT-E service kit / Software installation / Service DUT-E utility installation
3.4.2 Service DUT-E utility installation
Insert CD Service DUT-E into CD-ROM (DVD-ROM) and run installation file Setup Service
DUT-E vX.XX.exe.
Note — X.XX corresponds to the version of utility. The latest version described in the present manual is 3.25.
Select installer language out of the drop-down list (see Figure 34).
Figure 34 — Installer language selection
Click button to start installation of the utility (see Figure 35) and follow the instructions.
Figure 35 — Service DUT-E installation wizard window
DUT-E fuel level sensors
Operation manual. Version 6.0 58
Configuration with SK DUT-E service kit / Software installation / Service DUT-E utility installation
The following window will indicate the process of installation of Service DUT-E files (Figure 36)
Figure 36 — Installation progress
Since the installation of Service DUT-E utility is finished PC is ready for SK DUT-E connection and operation (see Figure 37).
Figure 37 — Successful completion of Service DUT-E installation
DUT-E fuel level sensors
Operation manual. Version 6.0 59
3.5 SK DUT-E connection
3.5.1 Exterior inspection prior to connection
It is necessary to conduct SK DUT-E exterior inspection for the presence of the possible defects arisen during transportation, storage or careless use:
• visible damages of the adapter body and connectors;
• connector and insulation damages of service cables and USB A-B cable.
Contact the supplier if any defects detected.
DUT-E fuel level sensors
Operation manual. Version 6.0 60
Configuration with SK DUT-E service kit / SK DUT-E connection / Operation restrictions
3.5.2 Operation restrictions
Avoid the following when connecting SK DUT-E to the sensor mounted into the fuel tank of the vehicle:
•
• ingress of fuel and lubricants and moisture to the contact pins of adapter slots or connectors of service cables and USB A-B cable; potential damage of the adapter and cables by the rotating and heating elements of the engine.
ATTENTION: To avoid any SK DUT-E faults in communication between PC and sensor make sure there are no sources of electromagnetic interference close to the workplace
(running electric motors, welding equipment, high-power transformers, power lines, etc).
DUT-E fuel level sensors
Operation manual. Version 6.0 61
Configuration with SK DUT-E service kit / SK DUT-E connection / Connecting DUT-E to PC
3.5.3 Connecting DUT-E to PC
ATTENTION: Power down the electrical system of the vehicle prior to DUT-E connecting to the PC. Use the battery switch or take off the battery contact terminals.
DUT-E sensors are connected to PC through SK DUT-E according to the connection schemes
(see Figure 38).
Follow the instructions:
1) Plug DUT-E to RS-232/ISO 9141/RS-485 adapter slot with the proper service cable according to DUT-E model.
2) Plug the adapter to USB port of PC with the USB A-B cable*.
3) Connect power supply and ground wires to vehicle electrical system or battery.
Notes
1 Power is supplied from USB port of the PC for DUT-E 232 and DUT-E 485.
2 External power supply (from the battery or power supply unit) is required for connection of
DUT-E AF and DUT-E CAN (see Figures 38a and 38b).
4) Power on the vehicle (battery).
*
Connecting the adapter to the PC's USB port is allowed both before and after the power
(battery) on and Service DUT-E utility launch.
DUT-E fuel level sensors
Operation manual. Version 6.0 62
Configuration with SK DUT-E service kit / SK DUT-E connection / Connecting DUT-E to PC
a) configuring DUT-E AF b) configuring DUT-E CAN c) configuring DUT-E 232 d) configuring DUT-E 485
Figure 38 —SK DUT-E connection schemes
DUT-E fuel level sensors
Operation manual. Version 6.0 63
Configuration with SK DUT-E service kit / Operation test
3.6 Operation test
If software installation and SK DUT-E connection have been made correctly Windows automatically detects adapter connected to PC’s USB port as USB device and enables virtual
COM port driver for it. The virtual COM port will be displayed in the list of ports of Windows
Device manager (see Figure 39).
ATTENTION:
1) It is recommended to use the same USB port of the PC for Service DUT-E connections.
2) Untick power save check box in virtual COM-port properties (see Figure 39). a) selecting port properties b) disabling power save option
Figure 39 — Virtual COM-port configuration in Device manager
SK DUT-E is ready to use since the power is on (vehicle electrical system or USB port of the
PC).
See Chart 16 for signal description of LED indicators located on the adapter body.
Chart 16 – LED signal description
LED indicator
Signal description
Marking Status and light color
ON
No signal
Power supply is on
(from vehicle electrical system)
Power supply is on (from USB)
Power supply is off or voltage is less than minimum required
DUT-E data is being received
RX
No signal No data from DUT-E
TX
No signal
Data is being transmitted to DUT-E
No data to DUT-E
DUT-E fuel level sensors
Operation manual. Version 6.0 64
Configuration with SK DUT-E service kit / Utility launch
3.7 Utility launch
Service DUT-E utility is launched with desktop shortcut created during installation.
Figure 40 shows Service DUT-E window with no adapter connected to PC’s USB port. The top left area shows connection status:
Wire connection – Disconnected
Firmware version – Unknown
Serial number - Unknown
Figure 40 — Service DUT-E main window with no connection to sensor
To enable connection between the sensor and PC connect adapter to USB port of PC and tick connection checkbox in the left from COM-port parameters field.
Note — when connecting DUT-E CAN/AF firstly select network address from the drop-down list
ADDR (see Figure 41).
Figure 41 — Network address selection for DUT-E CAN and DUT-E AF
Utility will automatically change the connection status to Connected. Firmware version, serial number of the DUT-E sensor, virtual COM port number will be displayed as well as baud rate
for RS-232, RS-485 or K-line connection (see Figure 41).
LED indicators of the adapter will display signals according to Chart 16.
DUT-E fuel level sensors
Operation manual. Version 6.0 65
Configuration with SK DUT-E service kit / Utility launch
Figure 42 — Service DUT-E main window with sensor connection established
DUT-E fuel level sensors
Operation manual. Version 6.0 66
Configuration with SK DUT-E service kit / User interface and initial setup
3.8 User interface and initial setup
Service DUT-E user interface consists of Horizontal menu, Vertical menu, Connection
status area and Information and configuration area (see Figure 43)
Connection status area
Information and configuration area
Vertical menu
Horizontal menu
Figure 43 — Service DUT-E user interface
The top left area is Connection status area which displays current connection status of the sensor (Connected/Disconnected), firmware version and serial number of the connected DUT-E sensor, network address selection drop-down list (ADDR) and firmware update button.
Note — network address selection drop-down list (ADDR) is not displayed when
DUT-E 232/485 connected.
Horizontal menu located under Connection status area provides following options:
• profile options (loading profile, saving profile, printing profile);
• selection of interface language.
Vertical menu is located at the left side of the window and used for selection of sensor profile entries which are displayed in Information and configuration area at the right side of the window.
Vertical menu also contains Diagnostics and Fuel tank calibration entries.
The only initial setting required is selection of user interface language.
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Operation manual. Version 6.0 67
Configuration with SK DUT-E service kit / DUT-E profile / Load profile
3.9 DUT-E profile
Service DUT-E utility is designed for managing DUT-E sensor profile (hereinafter profile).
Profile is combination of specification data, configurations and settings of DUT-E sensor and vehicle it is mounted on.
Utility can operate profiles in both DUT-E connected and autonomous modes. In autonomous mode previously saved profiles can be loaded and modified.
ATTENTION: The following Service DUT-E operation description is compiled for DUT-E connected mode. While in autonomous mode of Service DUT-E some features and options are not available.
Profile can be saved as a file on PC’s hard drive or saved to internal memory of connected
DUT-E or printed if this is required.
3.9.1 Load profile
The following options of profile loading are available on
(see Figure 44):
• From disk;
• Default;
• From sensor.
button click
Figure 44 — Profile loading
Previously saved profile can be loaded from hard drive or removable disk when From disk option is.
Profile with default DUT-E settings is loaded when Default option is selected. This profile lets the user to get acquainted with utility without establishing sensor connection.
Profile of the connected DUT-E sensor is loaded when From sensor option is selected.
ATTENTION: File extension of DUT-E profile is .dpf
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Operation manual. Version 6.0 68
Configuration with SK DUT-E service kit / DUT-E profile / Save profile
3.9.2 Save profile
The following options of profile saving are available on
(see Figure 45):
• To file;
• To sensor.
button click a) selection of saving option
Figure 45 — Saving profile
b) profile saved
Select file location and enter file name when saving profile To file. The saved profile can be uploaded to any other DUT-E sensor of the same modification.
All the setting modifications will be saved to sensor’s internal memory when saving profile To
sensor.
The utility will prompt authorization dialogue (see 3.10.2
) on saving profile to sensor or on
calibration if user has not been yet authorized (see Figure 46).
Figure 46 — Password request
Note — default password for DUT-E sensors is 1111. It is stated in sensor specification in factory settings list.
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Operation manual. Version 6.0 69
Configuration with SK DUT-E service kit / DUT-E profile / Print profile
3.9.3 Print profile
This feature converts loaded profile into HTML document.
After clicking button select location for saving of *.html file with sensor profile data. Then this file can be viewed or printed.
DUT-E profile printed copy example.
RECOMMENDATION: It is recommended to attach profile hard copy to sensors
Specification for further tracking of setting modifications made for particular sensor.
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Operation manual. Version 6.0 70
Configuration with SK DUT-E service kit / Vertical menu description / Passport
3.10 Vertical menu description
3.10.1 Passport
When the profile is loaded from the connected sensor Passport entry shows the following information on connected DUT-E (see Figure 47):
• sensor model;
• serial number;
• firmware version.
This data cannot be edited by the user. Serial number and firmware version is also displayed at Connection status area of the window.
Figure 47 — Passport module
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Operation manual. Version 6.0 71
Configuration with SK DUT-E service kit / Vertical menu description / Authorization
3.10.2 Authorization
Authorization module provides access to DUT-E settings modification.
Service DUT-E users can be divided into two groups:
• guest — can view DUT-E settings but cannot modify them;
• specialist — can view and modify DUT-E settings.
Unauthorized user has guest rights. To get specialist rights user should log in with current password (see 3.9.2) and click button (see Figure 48). a) Authorization with current password b) Successful authorization notification c) Invalid password notification
Figure 48 — User authorization
To set new password enter current password, tick new password box, enter new password and click button (see Figure 49). a) Entering new password b) Confirmation of successful
password modification
Figure 49 — Setting new password
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Operation manual. Version 6.0 72
Configuration with SK DUT-E service kit / Vertical menu description / Authorization
ATTENTION:
Contact Technoton technical support at support@technoton .by if the password is lost.
Requirements for password recovery request:
• scan copy of the request signed and sealed by the official representative of the company the sensor been purchased by should be attached;
• request should contain serial number and manufacture date of the sensor;
• email should contain password recovery code in a text form (not a screenshot!);
• email should contain full name and contact e-mail of a person who should receive the recovered password
To generate password recovery code (see Figure 50) use Ctrl+F10 shortcut in the current password field of authorization dialogue (see Figure 46).
Figure 50 — Generating password recovery code
DUT-E fuel level sensors
Operation manual. Version 6.0 73
Configuration with SK DUT-E service kit / Vertical menu description / Settings - Calibration
3.10.3 Settings - Calibration
Calibration is required for correct operation of DUT-E . Calibration is conducted to determine minimum and maximum levels of measurement of fuel in the tank.
ATTENTION: All DUT-E sensors are factory calibrated! Recalibration is required only since the sensor’s measuring probe been cut or extended with additional sections.
To calibrate minimum and maximum level follow the procedure:
1) Get the measuring probe (tubes) out of the fuel.
2) Wait for 30…60 seconds so that all the fuel run off the probe.
3) Measure the probe length L (mm) from the edge to the drain holes (see Figure 51a).
4) Enter the value into Actual length of sensor after trimming field of Settings-Calibration entry (see Figure 51b).
5) Wait for 3…5 seconds for sensor readings stabilization.
6) Click for minimum level calibration.
7) Dip the probe’s tubes fully into the fuel.
8) Wait for 3…5 seconds for sensor readings stabilization.
9) Click for maximum level calibration.
10) Min/max calibration is finished.
a) measuring probe length b) Settings-Calibration entry
Figure 51 — DUT-E min/max calibration
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Operation manual. Version 6.0 74
Configuration with SK DUT-E service kit / Vertical menu description / Settings - Operation modes
3.10.4 Settings – Operation modes
Operation modes entry contains settings to configure sensor for operation in particular conditions with compliance of tracking device requirements (see Figure 52). a) DUT-E AF b) DUT-E CAN c) DUT-E 232/485 d) Automatic transmission mode drop-down list e) Summator mode
drop-down list
Figure 52 — Operation mode configuration
1) Fuel level filter time — time interval preceding the data transmission. Fuel level value is smoothed during this interval. Thus fuel level value transmitted by sensor to the tracking device is not instantaneous and is averaged over a certain period of time.
Parameter value range
Default value is 60 seconds. is 0…120 seconds with 10 seconds step.
Setting this parameter is very important for DUT-E mounted on vehicles operated on hilly surfaces.
2) Message interval* — time period the sensor automatically send output message to the tracking device.
Parameter value range
Default value is 1 second. is 1…60 seconds with 1 seconds step.
3) Automatic transmission mode* – defines sensor output message type:
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Operation manual. Version 6.0 75
Configuration with SK DUT-E service kit / Vertical menu description / Settings - Operation modes
• Off – no automatic message transmission, sensor waits for tracking device request;
• HEX - automatic message transmission in binary format (used by default);
• ASCII - automatic message transmission in text format;
• ASCII EXT – automatic message transmission in extended text format. Additional Prefix and Postfix configurable parameters are available for this mode to insert required header or ending of the message.
4) Address ** - provides DUT-E with network address when several operate via single bus
(network).
The following addresses are set by the Manufacturer by default:
• DUT-E 485 — two last digits of the sensor serial number;
• DUT-E CAN and DUT-E AF — 101.
5) Summator*** — sets sensors network status when working in CAN summator mode
(see Figure 52e):
• Off —
(default value); no need to summarize sensor values
• Master — should be selected for a sensor which has the highest decimal address in the network;
• Slave — should be selected for all the other network sensors.
*
**
Only for DUT-E 232 and DUT-E 485.
Only for DUT-E 485, DUT-E CAN and DUT-E AF.
*** Only for DUT-E CAN.
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Operation manual. Version 6.0 76
3.10.5 Settings – Thermal compensation
Thermal expansion / contraction of the fuel caused by the temperature deviation, alters the volume of fuel in the tank. As a consequence, the sensor transmits a significant increase or decrease of fuel level to the tracking device. DUT-E electronics makes thermal correction calculation which compensates fuel expansion / contraction. As a result the output values are normalized to 20 °C temperature and are not altered during further temperature deviations.
Automatic thermal compensation is disabled by default. To enable it tick the checkbox in
Thermal compensation tab. Then insert the required coefficient value into the field that appears on the right side (see Figure 53).
a) disabling the feature b) inserting coefficient
Figure 53 — Thermal compensation setting
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Operation manual. Version 6.0 77
Configuration with SK DUT-E service kit / Vertical menu description / Settings - Output message
3.10.6 Settings – Output message
One of the following output value types available for DUT-E 232 and DUT-E 485 (see Figure 54):
• fuel level in standard (normalized) units (0...1000);
• fuel level in millimeters (mm), 0.1 mm step;
• fuel volume in liters (L), 0.1 L step;
• fuel volume in percentage (%), 0.4% step.
Figure 54 — Selection of output value type for DUT-E 232/485
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Operation manual. Version 6.0 78
Configuration with SK DUT-E service kit / Vertical menu description / Settings - Calibration table
3.10.7 Settings – Calibration table
This entry is used to record fuel tank calibration into the sensor internal memory. The table is filled out with the data achieved during fuel tank calibration procedure (see DUT-E Installation
Manual document).
The data is entered as a table of correspondence between measured fuel level value (Fuel level
(mm) field) and fuel volume in the tank (Volume (L) field). Recommended number of table entries is 15. Max possible is 30 entries (see Figure 55).
Figure 55 — Calibration table
Click button to insert a new entry into the table and fill out the fields. Entries are automatically sorted from low to high fuel level value. To delete an entry highlight it and click
button.
Clicking button will allow saving the table as a *.ttd file. To load previously saved table from. file click button.
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Operation manual. Version 6.0 79
Configuration with SK DUT-E service kit / Vertical menu description / Settings - Interface
3.10.8 Settings - Interface
Interface module (see Figure 56) provides selection of baud rate for RS-232 (for DUT-E 232),
RS-485 (for DUT-E 485) and K-line (for DUT-E CAN and DUT-E AF) connections out of drop-
down list:
• 4800 bit/s;
• 9600 bit/s;
• 19200 bit/s.
Figure 56 — Interface setting
DUT-E fuel level sensors
Operation manual. Version 6.0 80
Configuration with SK DUT-E service kit / Vertical menu description / Settings – Analog output
3.10.9 Settings – Analog output
Analog output* module of Service DUT-E used for configuration of DUT-E AF output voltage range according to the voltage range of the tracking device input (see Figure 57). a) selection of signal type b) value type selection c) enabling diagnostics values of output signal
Figure 57 — DUT-E AF output configuration
The first drop-down list is for selection of Output signal according to 1.4.2
• U (voltage);
• F (frequency).
The second drop-down list for configuring value type:
• Level (fuel level in the tank);
• Volume (fuel volume in the tank);
•
Sum (totalizing readings of several sensors according to 2.8.2
* Only for DUT-E AF.
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Operation manual. Version 6.0 81
Configuration with SK DUT-E service kit / Vertical menu description / Settings – Analog output
To configure analog output follow the instructions:
1) Enter value of the lower range limit into “Minimum level (1.0…8.0V)” field.
2) Enter value of the higher range limit into “Maximum level (2.0…9.0V)” field.
Diagnostics drop-down list (see Figure 57c) allows to enable/disable special output signal diagnostics values:
• On — for U mode 0.5 V and 9.5 V voltage are diagnostics values according to Chart 22.
For F mode 400 Hz and 1600 Hz frequency are diagnostics values according to
Chart 23.
• Off — special diagnostics output values are disabled. Default setting.
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Configuration with SK DUT-E service kit / Vertical menu description / Diagnostics
3.10.10 Diagnostics
Diagnostics module is used to view the current values and information on possible malfunction of the sensor (see Figure 58a).
Values displayed in “Fuel level (mm)” can be used for fuel tank calibration.
Analyzing the values of the parameters (fuel level in millimeters, standard units and liters) the correctness of the calibration and sensor settings can be verified.
Diagnostics tab will display the following information if there any malfunction:
• malfunction code;
• transcript of the malfunction code;
• possible malfunction reason.
DUT-E COM includes malfunctions codes according to Chart 17. a) displaying current values and malfunction info b) logging current values
Figure 58 — Diagnostics module
For analysis of sensor data it is possible to log the values into the file. Recording interval is about 1 second. To log data enter a number of required log entries into N field of Log area and click . Click to stop logging.
Recorded log files (*.txt) are automatically stored to \DUT_LOG folder of the utility installation directory on PC. File name consists of sensor serial number, date and time of log start.
See Annex F for a log file instance.
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Operation manual. Version 6.0 83
Configuration with SK DUT-E service kit / Vertical menu description / Diagnostics
Chart 17 — Malfunction codes
Malfunction code
Firmware version up to 2.9
Firmware version 2.9 and higher
255
254
253
252
Transcript of the malfunction code
Possible solution
128 (-128)*
Calibration error
Check if the measuring probe actual size value is inserted correctly and (or) recalibrate the sensor**
129 (-127)*
130 (-126)*
131 (-125)*
Short circuit in measuring probe tubes
Wash the measuring probe tubes with clean fuel, clean fuel tank of mud and water.
Calibration error
Check if the measuring probe actual size value is inserted correctly and (or) recalibrate the sensor**
Contact your supplier
251 132 (-124)* Hardware failure
250 133 (-123)*
Calibration error
Check if the measuring probe actual size value is inserted correctly and (or) recalibrate the sensor**
— 134 (-122)*
* Different malfunction code display.
** Fuel tank calibration table should be recompiled and recorded all over again into sensor internal memory.
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Operation manual. Version 6.0 84
Configuration with SK DUT-E service kit / Firmware update
3.11 Firmware update
DUT-E firmware update procedure is started on button click. The button is located at Connection status area of Service DUT-E window (see Figure 59).
Figure 59 — Firmware update window
To cancel firmware update click button. To continue with firmware update click
and select firmware file (*.cod) from the PC hard drive (see Figure 60).
Figure 60 — Opening firmware file
ATTENTION: Check the details of firmware file to make sure it matches DUT-E modification!
Enter sensor password into the prompted dialogue window (see Figure 61).
Figure 61 — Password request window
Firmware update process can last for several minutes (see Figure 62).
ATTENTION:
Before the end of the update process it is ABSOLUTELY FORBIDDEN to
1) Disconnect DUT-E from the adapter.
2) Disconnect adapter from the PC.
3) Power down the PC.
4) Run any resource-intensive applications on the PC.
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Operation manual. Version 6.0 85
Configuration with SK DUT-E service kit / Firmware update
Figure 62 — Firmware file uploading to the sensor memory
Service DUT-E will display the new firmware version at Connection status area in case the update is successful. DUT-E is ready for further operation.
In case of any error occur check all the cable and adapter connections and retry. Contact
Technoton technical support at support@technoton.by
if another try is also unsuccessful.
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Operation manual. Version 6.0 86
Configuration with SK DUT-E service kit / Utility shutdown and DUT-E disconnection
3.12 Utility shutdown and DUT-E disconnection
When configuration is made follow the instructions to disconnect DUT-E :
1)
Save modified profile if necessary (see 3.9.2
2) Shutdown Service DUT-E utility clicking at the top left corner of the window.
3) Power down vehicle electrical system if the sensor is powered from it or switch off power supply of the sensor*.
4) Disconnect DUT-E service cable from the sensor connector.
SK DUT-E
can now be used for the next sensor connection (see 3.5.3
* This step is only applied for DUT-E CAN and DUT-E AF.
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Operation manual. Version 6.0 87
Configuration with SK DUT-E service kit / SK DUT-E disconnection
3.13 SK DUT-E disconnection
When works is done follow the instructions to disconnect SK DUT-E form the PC:
1) Disconnect USB A-B cable from USB port of the PC.
2) Disconnect USB A-B B cable from USB port of the adapter.
3) Disconnect DUT-E service cable from RS-232/ISO 14230/RS-485 port of the adapter.
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Operation manual. Version 6.0 88
Configuration with SK DUT-E service kit / Uninstalling Service DUT-E utility
3.14 Uninstalling Service DUT-E utility
To uninstall Service DUT-E utility follow the instructions:
1) Select “Service DUT-E 3.22” folder at Start → All Programs menu of Windows.
2) Run Uninstall shortcut in the selected folder.
3) Follow the instructions of the uninstallation wizard.
All the files related to Service DUT-E utility will be deleted from the PC when the uninstallation process finishes.
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Operation manual. Version 6.0 89
Measurement accuracy check / Basic principles
4 Measurement accuracy check
4.1 Basic principles
DUT-E accuracy check test is conducted to determine the reduced and absolute error of fuel
level measurement on the particular vehicle .
The procedure of DUT-E accuracy check requires filling/draining of the fuel tank and comparing sensor data with the actual amounts of filling/draining.
Fuel drain is carried with manual or mechanical pump.
Calibrated measuring containers must be used to determine the exact amount of drained/refilled fuel.
ATTENTION: The amount of any fuel filling/draining during the accuracy test should not be less than 20% of total tank capacity.
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Operation manual. Version 6.0 90
Measurement accuracy check / Check tests procedure
4.2 Check tests procedure
Check tests should be carried out in the following order:
1) Turn ignition on.
2) Drain a fixed volume of fuel.
3) Determine the exact amount of fuel with the calibrated measuring container.
4) Record the data into the Check test report.
5) Wait for the fuel getting still in the tank (for a stable DUT-E readings).
6) Refuel the tank with the previously drained fuel.
7)
8)
Record the data into the Check test report.
When analyzing accuracy errors, "Drain" and "Refill" parameters are estimated as a percentage relative to the total tank capacity.
See Annex A for check test report template and error calculation formula.
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Operation manual. Version 6.0 91
Accessories / MK DUT-E mounting kit
5 Accessories
Technoton offers high quality accessories for mounting, connection and operation of DUT-E sensors.
5.1 MK DUT-E mounting kit
DUT-E mounting kit (hereinafter MK DUT-E ) is used for sensor mounting into the fuel tank of vehicle or stationary tank. MK DUT-E is included into DUT-E delivery set. Extra mounting kits can be ordered separately if required. DUT-E sensor is mounted quickly and accurately with
MK DUT-E.
See Figure 63 for MK DUT-E components.
By default bores are positioned according to CIS vehicle standard. Mounting plate with SAE 5 bolt standard bore position can be preordered.
5
6
7
8
9
1
2
3
4
1 2 3 4 5 6
- plastic mounting plate
- rubber gasket the plastic mounting plate
- sealing rubber ring for the plastic mounting plate
- DUT-E bottom stop
- bolt
- self-tapping screw
- plastic seal
- sealing cord
- screen filter
Figure 63 — MK DUT-E mounting kit
7
* 1 pc. – used for DUT-E installation and 1 pc. is a spare part.
8 9
– 1 pc.;
– 2 pcs.*;
– 2 pcs.*;
– 1 pc.;
– 5 pcs.;
– 5 pcs.;
– 2 pcs.;
– 2 pcs.;
– 1 pc.
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Operation manual. Version 6.0 92
Accessories / US-1 adapter unit
5.2 US-1 adapter unit
In case DUT-E is mounted as a replacement of the factory installed float sensor the fuel gauge in the vehicle cabin does not operate any more. To enable the fuel gauge working with DUT-E
US-1 adapter unit is used (see Figure 64)
ATTENTION: Adapter unit can only operate with DUT-E A5 or DUT-E AF with
1.5…4.5V configured output signal.
Chart 18 — Adapter unit modifications
Order code
US-1-90
US-1-800
Description
Fuel level sensor emulation with low resistance: 0-90 Ohm.
When fuel level increases, resistance increases as well
Fuel level sensor emulation with high resistance: 800-185 Ohm.
When fuel level increases, resistance decreases
Figure 64 — US-1 adapter
Electrical connection of US-1 is carried out in compliance with wire assignment according to
Chart 19.
Chart 19 — US-1 wires assignment
Wire number Wire marking Wire color*
1 T034 White
2 GND Brown
3 T734 Pink
4 T733 Pink
5 VBAT Orange
* The manufacturer reserves the right to change wire colors.
Assignment
Fuel level sensor signal
(input)
Ground
Fuel level indicator
(output)
Fuel level warning lamp
(output)
Power supply “+”
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Operation manual. Version 6.0 93
5.3 Screen filter
Screen filter is mounted on the measuring probe tubes of DUT-E (see Figure 65a) to protect measuring probe electrodes from mud and water. Using the filter extends significantly faultless lifetime of the sensor (see DUT-E screen filter video).
Screen filter mounting order: firstly put on fixator, then put on bottom stop and fix it with two side screws. Put the screen filter over bottom stop and fasten it with a fixator locks.
(see Figure 65b).
Screen filter a) Mounting location
Fixator b) Mounting order
Figure 65 — Screen filter
Bottom-stop
DUT-E fuel level sensors
Operation manual. Version 6.0 94
Accessories / Connection cables
5.4 Connection cables
The following connection cables are used for DUT-E electrical connection (Chart 20):
Chart 20 — DUT-E connection cables
View
Indication
(order code)
Cable 076-01
(sensor cable)
Function and description
To connect sensors to recording and display units and to external power supply.
Length – 7.5 m
Cable 084
(extension for cable 076-01)
To extend the length of
076-01 cable.
Length – 3 m
Cable DUT-E-232/485
(sensor connection cable)
To connect the sensors to recording and display units and to external power supply.
Length – 7 m
RS 2AMP-300
(232/485 cable
extender)
RS 2AMP-1000
(232/485 cable
extender)
S6 SC-CW-700
(cable)
To extend the length of cable
DUT-E-232/485.
Length – 3 m
To extend the length of cable
DUT-E-232/485.
Length – 10 m
To connect DUT-E CAN sensors to recording and display units and to external power supply.
Length – 7 m
DUT-E fuel level sensors
Operation manual. Version 6.0 95
Accessories / Additional accessories
5.5 Additional accessories
Additional accessories may be required for DUT-E
(see Chart 21).
Chart 21 — DUT-E Additional accessories
View Name Description Application
Catch DUT-E Bottom-stop
To enhance DUT-E mounting rigidity
FTP DUT-E Fuel tank plug
Bayonet plug for temporary DUT-E replacement
Plug
Plug for DUT-E mounting hole
To plug fuel tank opening
CRYSTAL seal
(100pcs per pack)
UNIVERSAL sealing rope
(50m per reel)
Plastic seal,
100pcs per pack
Sealing DUT-E mounting and cable connection
Sealing cord
CoTube9.8
(50m per reel, Ø 9.8 mm)
Split corrugated tubing
Fast assembly plastic tube for DUT-E cable protection
Connector 5200
(3x0.8 mm², 85 pcs. per pack)
Quick splice connector
For DUT-E electrical connection
DUT-E fuel level sensors
Operation manual. Version 6.0 96
Diagnostics and troubleshooting / DUT-E with analog output
6 Diagnostics and troubleshooting
In case of any malfunction first of all examine condition of vehicle power supply system and
power supply pins condition of the DUT-E connector.
WARNING:
1) Severe contact corrosion of chassis ground connection switch or its malfunction can seriously affect DUT-E output signal.
2) DUT-E readings will be invalid if the measuring tubes are closed by conducting mud or water.
6.1 DUT-E with analog output
Normal operation of analog DUT-E sensors can be verified with a multimeter by measuring their output voltage (for DUT-E AF/A5/A10) or current (for DUT-E I) and comparing the measurement results with the data of Chart 22.
Chart 22 — Analog DUT-E malfunctions
Output signal value Malfunction reason Solution
Voltage: from 1 to 9 V (for DUT-E AF) from 0.4 to 5.0 V (for DUT-E A5); from 0.4 to 10.0 V (for DUT-E A10)
Current:
2…22 mA (for DUT-E I)
Voltage: from 9.5 to 10 V (for DUT-E AF) over 5 V (for DUT-E A5); over 10 V (for DUT-E A10)
Current:
Over 22 mA (for DUT-E I)
No malfunctions, normal operation
Short circuit of the measuring probe tubes due to metal shavings and burrs, conductive mud or water at the bottom of the fuel tank
Check tracking device operation
Eliminate short circuit, wash the tubes of the sensor, clean the fuel tank
Voltage: from 0.5 V and less (for DUT-E AF) less than 0.4 V (for DUT-E A5 and
DUT-E A10)
Current: less than 2 mA (for DUT-E I)
* Only for DUT-E AF
Sensor is not calibrated* Calibrate the sensor*
Sensor PCB failure Contact the closest service center
Diagnostics of DUT-E AF can be carried out with SK DUT-E service kit the same way as for
other DUT-E modifications having digital output (see 6.3
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Operation manual. Version 6.0 97
Diagnostics and troubleshooting / DUT-E with frequency output
6.2 DUT-E with frequency output
Normal operation of frequency DUT-E can be verified with frequency meter by measuring output sensor frequency and comparing results of measurements with the data in Chart 23.
Chart 23 — Frequency DUT-E malfunctions
Output frequency, Hz from 500 to 1500
1600
400
Malfunction reason
No malfunctions, normal operation
Short circuit of the measuring probe tubes due to metal shavings and burrs, conductive mud or water at the bottom of the fuel tank
Solution
Check tracking device operation
Eliminate short circuit, wash the tubes of the probe, clean the fuel tank
Sensor is not calibrated Calibrate the sensor
Sensor PCB failure Contact the closest service center (RSC)
Diagnostics of DUT-E AF can be carried out with SK DUT-E service kit the same way as for
other DUT-E modifications having digital output (see 6.3
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Operation manual. Version 6.0 98
Diagnostics and troubleshooting / DUT-E with digital output
6.3 DUT-E with digital output
Normal operation of digital DUT-E sensors is verified with the help of SK DUT-E service kit
DUT-E fuel level sensors
Operation manual. Version 6.0 99
Maintenance / General instructions
7 Maintenance
7.1 General instructions
DUT-E visual inspection and operation check is recommended at least once per year.
ATTENTION: Replace the sealing ring of the mounting plate with a new one when remounting DUT-E.
DUT-E repair works are carried out only by certified Regional Service Centers
(hereinafter, RSCs). Full RSCs list can be found at www.jv-technoton.com
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Operation manual. Version 6.0 100
7.2 Demounting
Clean the tank surface nearby the mounting location before DUT-E demounting.
Prepare a clean napkin to clean the fuel from the sensor probe.
Cut the sealing cord carefully, with no damage to connection cable.
Disconnect DUT-E cable connector.
Unfasten DUT-E by turning its body counterclockwise.
Mount the fuel tank plug (be ordered separately) for protection from any possible clogging through mounting opening.
ATTENTION: To avoid any cable/PCB damage do not pull the interface cable when demounting DUT-E.
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Operation manual. Version 6.0 101
7.3 Examination
Since DUT-E is demounted conduct a visual examination to detect the following defects:
• visible damages of the sensor head body, measuring probe, interface cable, cable;
• backlash of measuring unit tubes relative to each other and/or the body;
• presence of mud or paraffin between the tubes of the measuring probe;
• damage of the plastic mounting plate and traces of fuel leaks through the rubber gasket of the mounting plate.
Contact RSC
Manufacturer if the defects detected.
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Operation manual. Version 6.0 102
7.4 Cleaning
During DUT-E operation mud or paraffin formation is possible on the surface of the measuring probe pipes. Pollution of the cavity between the pipes of the measuring probe can lead to significant increase of accuracy error.
ATTENTION: Mud coating inside the inner measuring tube does not affect DUT-E normal operation. Examine the space between the tubes for mud and paraffin.
To clean the tubes wash them with the clean fuel.
It is also recommended to wash the screen filter as well.
ATTENTION: Avoid fuel getting on DUT-E head body, interface cable and its connector when washing the tubes.
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Operation manual. Version 6.0 103
8 Packaging
DUT-E and SK DUT-E delivery sets come in cardboard boxes of the following shape (Figure 66)
a) DUT-E b) SK DUT-E
Figure 66 — Packaging
Label sticker with information on the product name, size, serial number, hardware version, manufacture date, weight and Quality Control seal is stuck on two sides of the DUT-E box.
(see Figure 67a ).
Label sticker with information on the product name, serial number, software Service DUT-E version, manufacture date, weight and Quality Control seal is stuck on two sides of the SK
DUT-E box. (see Figure 67b ).
a) DUT-E b) SK DUT-E
Figure 67 — Packaging label
Note — label design and contents can be modified by the Manufacturer.
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Operation manual. Version 6.0 104
9 Storage
DUT-E is recommended to be stored in dry enclosed areas.
DUT-E storage is allowed only in original packaging at temperature range from -50 to +40° C and relative humidity up to 100% at +25° C.
Do not store DUT-E in the same room with substances that cause metal corrosion and / or contain aggressive impurities.
DUT-E shelf life must not exceed 24 months.
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Operation manual. Version 6.0 105
10 Transportation
Transportation of DUT-E is recommended in closed transport that provides protection for
DUT-E from mechanical damage and precipitation.
When transporting by air, DUT-E must be stored in heated pressurized compartments.
Air environment in transportation compartments should not contain acid, alkaline and other aggressive impurities.
Shipping containers with packed DUT-E sensors should be sealed.
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Operation manual. Version 6.0 106
11 Utilization/re-cycling
DUT-E does not contain harmful substances and ingredients that are dangerous to human health and environment during and after the end of life and recycling.
DUT-E does not contain precious metals in amount that should be recorded.
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Operation manual. Version 6.0 107
Contacts
Distribution, technical support and service
Technoton JV
Phone/fax: +375 17 298 10 02
+375 17 223 78 20 info@jv-technoton.com support@technoton.by
Manufacturer
Zavod Flometr
Phone/fax : +375 1771 3-99-89 office@flowmeter.by
DUT-E fuel level sensors
Operation manual. Version 6.0 108
Annex A Template of check test report
Annex A
Template of check test report
Report
Date: ___________________
DUT-E model and serial number
Vehicle type, model, registration number
Tracking/displaying device model and serial number
According to calibrated container
V
M
, liters
Drainage volume
According to tracking device V track
, liters
Absolute error Δ
=
V track
−
V
M
, liters
Accuracy error
Normalized to total tank volume
δ
=
V track
−
V
M
V total_volu me
⋅
100%
Refueling volume
According to calibrated container
V
M
, liters
Accuracy error
According to tracking device
V
track
, liters
Absolute error Δ
=
V track
−
V
M
, liters
Normalized to total tank volume
δ
=
V track
−
V
M
V total_volu me
⋅
100%
Resume:
The results of drain measurement match / do not match specifications.
The results of refueling measurement match / do not match specifications.
Comments: ___________________________________________________ representative of the CUSTOMER: __________________/____________________/ representative of the CONTRACTOR: __________________/____________________/
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Operation manual. Version 6.0 109
Annex B DUT-E CAN connection options
Annex B
DUT-E CAN connection options
Figure B.1 — Connection of one DUT-E CAN fuel level sensor to a recording and display unit incompatible with S6 cable system
DUT-E fuel level sensors
Operation manual. Version 6.0 110
Annex B DUT-E CAN connection options
Figure B.2 — Connection of several DUT-E CAN fuel level sensors to a recording and display unit incompatible with S6 cable system
DUT-E fuel level sensors
Operation manual. Version 6.0 111
Annex B DUT-E CAN connection options
Figure B.3 — Connection of one DUT-E CAN fuel level sensor to a recording and display unit compatible with S6 cable system
DUT-E fuel level sensors
Operation manual. Version 6.0 112
Annex B DUT-E CAN connection options
Figure B.4 — Connection of several DUT-E CAN sensors to recording and display unit compatible with S6 cable system
DUT-E fuel level sensors
Operation manual. Version 6.0 113
Annex C Message format of DUT-E CAN data transfer protocol
Annex C
Message format of DUT-E CAN data transfer protocol
See Chart C.1 for parameters, structure and contents of DUT-E CAN protocol messages.
Chart C.1 — Message description of DUT-E CAN data exchange protocol
Message parameters Message content
N o Message name
1 PGN 62982
“Fuel tank level and volume”
1 s 8 0 0 246 6 6 62982
(0xF606)
1
3
5
2 bytes Fuel level (0.1 mm)
2 bytes Fuel volume in the tank
( 0.1 L)
2 bytes Reserve
521023
521024
521025
7
8
1 byte Fuel temperature
(step 1 °C, offset 40 °C)
Example: 0 value stands for temperature of -40 °
C
1 byte Reserve
174
524000
2 PGN 62995
“DUT-E CAN passport”
On
request
45 0 0 246 19 6 62995
(0xF613)
1
17
25
33
41
44
16 bytes
Serial number
DUT-E CAN
8 bytes
Firmware version
DUT-E CAN
8 bytes
8 bytes
4 bytes
1 byte
Hardware version
DUT-E CAN
Settings version
DUT-E CAN
Production date
DUT-E CAN
DUT-E CAN address in the
CAN bus
521120
521121
521123
521124
521125
521188
— the bytes are not used at the moment
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Operation manual. Version 6.0 114
Annex C Message format of DUT-E CAN data transfer protocol
Chart B.1continued
Message parameters
N o Message name
Message content
3 PGN 63008
“DUT-E CAN status”
1000 ms
8 0 0 246 32 6 63008
(0xF620) 1.1
1.3
1.5
1.7
2.1
2.3
4.1
4.7
5.1
2.5
2.7
3.3
3.7
5.3
5.5
8
2 bytes
Ignition Key State 521049
2 bytes
Cross-Axle Blocking Status 521054
521059
2 bytes
PTO Switch Status
521136
2 bytes
Events Status
2 bytes
Active Faults Presence
Status
2 bytes
Passive Faults Presence
Status
2 bytes
Unit Power Status
521137
521138
521129
4 bytes
Engine Mode by Fuel Rate 521181
521180
4 bytes
2 bytes
4 bytes
Movement mode based on vehicle speed
Vehicle Fuel Saving Mode
Status
Axle Weight Mode
521139
521182
2 bytes
GPS/GLONASS Reciver
Status
2 bytes
GPS/GLONASS Antenna
Status
2 bytes
Modem Power Status
521134
521135
521130
2 bytes
Modem Registration Status 521131
524000
1 byte
Reserved_8
— the bytes are not used at the moment
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Operation manual. Version 6.0 115
Annex C Message format of DUT-E CAN data transfer protocol
Chart B.1continued
Message parameters
N o Message name
Message content
5 PGN 65226
«Active
Diagnostic
Trouble Codes
(DTC)
DUT-E CAN»
2 PGN 65276
“Dashboard”
3 PGN 65279
“Operator indicators”
1 s Vari able
- 0 254 202 6 65226
(0XFECA)
1 s
10000 ms
8
2
0 0 254 252 6 65276
(0xFEFC)
1
2
3-4
5
6
1
6 0 254 255 6 65279
(0xFEFF)
2
3
4
5-6
7-8
1.1
1.3
2.1
2.4
7-8 bits
5-6 bits
3-4 bits
1-2 bits
7-8 bits
5-6 bits
3-4 bits
1-2 bits
Reserve
2 bytes
6-8 bits
SPN 523000 (see Chart C.2)
16 high valuable bits
SPN 523000 (see Chart C.2)
3 low bits
1-5 bits
FMI malfunction codes
(see Chart C.2)
8 bit Reserve. Value equals 0
Counter.
1-7 bits
Value is 127 if counter is used.
Value varies from 0 to 126 if counter is not used
1 byte Reserve
1 byte Fuel level
1 byte
1 byte
2 bytes
Reserve
2 bytes
2 bits Water in Fuel Indicator
(1 – yes; 0 – no)
2 bits Operator Shift Prompt
3 bits Driver Warning System
Indicator Status
3 bits Emission Control System
Operator Inducement
Severity
1215
1706
80
96
95
99
169
-
97
5675
5825
5826
987
624
623
1213
3041
3040
3039
3038
1214
1216
— the bytes are not used at the moment
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Operation manual. Version 6.0 116
Annex C Message format of DUT-E CAN data transfer protocol
DUT-E CAN data transfer protocol is using malfunctions codes (FMI) according to Chart C.2.
Chart C.2 — DUT-E CAN malfunctions codes (FMI)
Parameter number
(SPN)
Malfunction codes
(FMI)
Description Possible solution
523000
523000
523000
523000
13
4
12
0
Sensor is not calibrated (the difference between calibration frequencies of signal generator with minimum and maximum fuel levels is less than 100 Hz)
Sensor is not calibrated for maximum fuel level
Signal generator is not functioning. Possible short circuit in measuring probe tubes
Calibration values for minimum and maximum fuel levels in the sensor differ less than 5 Hz
Current frequency of the signal generator is more than fixed one when calibrating for minimum (the difference is more than 100
Hz)
Check if the measuring probe actual size value is inserted correctly and (or) recalibrate the sensor*
Wash the measuring probe tubes with clean fuel, clean fuel tank of mud and water.
Check if the measuring probe actual size value is inserted correctly and (or) recalibrate the sensor*
Check if the measuring probe actual size value is inserted correctly and (or) recalibrate the sensor*
* Fuel tank calibration table should be recompiled and recorded all over again into sensor internal memory
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Operation manual. Version 6.0 117
Annex D Several DUT-E CAN connection scheme for readings totalizing under RS-232 interface
Annex D
Several DUT-E CAN connection scheme for readings totalizing under RS-232 interface
Figure D.1 — Several DUT-E CAN connection scheme for readings totalizing under RS-232 interface
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Operation manual. Version 6.0 118
Annex E DUT-E profile printed copy
Annex E
DUT-E profile printed copy
Fuel level sensor
Passport
Model sensor
Serial number
Firmware version
Date compil
Time compil
Settings
Calibration
Actual length of sensor after trimming (mm)
Thermal compensation
Thermal compensation (-3...3 %/°C)
Operation mode
Fuel level filter time, 0..120 s step=10 s
Address (101..108)
Analog output
Level min. (1.0...8.0 V):
Level max. (2.0...9.0 V):
Output signal type:
Output signal type:
Diagnostics:
Calibration table
No Level, mm
001
002
003
0.0
63.9
130.4
004
005
006
007
215.0
300.0
408.6
510.5
008 603.7
009 685.0
Parameters of sensor calibration
Frequency of calibration "free", Hz
Frequency of calibration "free", Hz
Volume, L
0.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
80.0
DUT-E AF
092001302783
3.12
Mar 09 2015
08:33:05
685.0
0
0
101
1.000
9.000
U
Level off
2309.99
1200.94
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Operation manual. Version 6.0 119
Annex F
DUT-E log file
Filename: DUT_SN 092001302783 _D15.04.2015_T145012.txt
File contents:
____________________________________
1 2 3 4 5 6 7 8 9 10 11 Data field numbers
Data fields description:
1 — check point number;
2 — current time;
3 — ambient temperature (C°);
4 — initial measuring generator frequency (Hz);
5 — temperature compensated measuring generator frequency (Hz);
6 — fuel level (s.u);
7 — initial fuel level (mm);
8 — temperature compensated fuel level (mm);
9 — temperature compensated filtered fuel level (mm);
10 — fuel volume (L);
11 — fuel volume (%).
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Operation manual. Version 6.0 120
Annex G
Index
A
B
C
D
Diagnostics and troubleshooting
E
F
I
standard fuel sensor replacement
K
L
DUT-E fuel level sensors
Operation manual. Version 6.0 121
M
N
O
P
Purpose of use and application area
Probe cutting according to tank depth
S
Settings – Analog output DUT-E AF
Settings – Output message DUT-E 232/485
T
Technical specifications main specifications
DUT-E A5, DUT-E A10, DUT-E I output signal
DUT-E 232, DUT-E 485 output signal
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Operation manual. Version 6.0 122
Annex H
Videography
1) Video clip DUT-E 485 Fuel Level Sensor Installation.
Check out the link: https://www.youtube.com/watch?v=X0gUSF3dRWk
2) Video clip Length Extension of Measurement Part DUT-E Using Measuring Sections KDC
Check out the link: https://www.youtube.com/watch?v=dWuY_JJfhFw
3) Video clip Filter Screen of DUT-E Fuel Level Sensor
Check out the link: https://www.youtube.com/watch?v=B5dcYxGfSqQ
4) Animation DUT-E fuel level sensor
Check out the link: http://www.jv-technoton.com/fuel_level_sensor
5) Other Technoton videos are on the YouTube channel which is regularly updated: https://www.youtube.com/channel/UCq7EF3DHrgl7fOWB2ynsR-A
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Operation manual. Version 6.0 123
